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Manufacturing Process Dept of Mechanical Engineering 1 Manufacturing Process MANUFACTURING PROCESS The process of converting raw materials, components, or parts into finished goods that meet a customer's expectations or specifications is known as manufacturing process. Manufacturing commonly employs a man-machine setup with division of labor in a large scale production. CLASSIFICATION OF MACHINING PROCESS: The manufacturing processes can be classified as: 1. Forming Processes 2. Moulding Processes 3. Machining Processes 4. Assembly Processes 5. Finishing Processes. 1. Forming Processes: In the metal industry, some of the primary forming operations may take place such as the rolling of basic shapes in steel, aluminium etc. Some of the common shapes so obtained from these processes are bars, sheets, billets, I-beams etc. Which are stan•dard shapes. These shapes can be used for further processing. Other forming processes may be drop-forging, stamping, extrusion, press work, punching, drawing etc. 2. Moulding Processes: Some products require moulding processes such as sand casting, die-casting etc. to get basic shape or form which may or may not require further processing. The selection of the particular process will depend upon to size of the job, quantity to be produced, accuracy, and complexity desired and economy. Dept of Mechanical Engineering 1 Manufacturing Process 3. Machining Processes: Metal machining is accomplished through basic machine tool processes which involve the generation of cylindrical surfaces, flat surfaces, complex curves and holes. The machine tools selected to accomplish this task depend on the size and shape of the part to be machined, the quality of finish required and production rate required. The examples of such processes are: turning, shaping, drilling, boring, grinding etc. In these machining opera•tions metal is removed from the part in the form of small chips by the cutting action of tool. The cutting action is accomplished by either rotating or reciprocating action of the tool relating to the part. 4. Assembly Processes: These processes assemble the parts and materials using welding, riveting, soldering, brazing, mechanical fastening and adhesive joining etc. 5. Finishing Processes: These processes are carried out for the aesthetic aspects, to achieve accuracy, surface finish or to increase life of the product. Such processes include cleaning, blast•ing, deburring, puffing, honing, lapping, polishing, painting etc. Dept of Mechanical Engineering 2 Manufacturing Process INTRODUCTION TO CASTING PROCESSES Casting manufacturing is a process in which liquefied material, such as molten metal, is poured into the cavity of a specially designed mold and allowed to harden. After solidification, the work piece is removed from the die to undergo various finishing treatments or for use as a final product. Casting methods are typically used to create intricate solid shapes, and cast products are found in a wide range of applications, including automotive components, aerospace parts, electronics, mechanical devices, and construction supplies. Selection of Casting Processes Different casting processes are available for utilization, and their suitability is influenced by a number of factors including the following: 1. Quantity of castings 2. Manufacturing cost 3. Product material 4. Dimensional accuracy required 5. Surface finish required DIFFERENT TYPES OF CASTING PROCESSES: 1) Sand casting: also known as sand molded casting, is a metal casting process characterized by using sand as the mold material. The term "sand casting" can also refer to an object produced via the sand casting process. Sand castings are produced in specialized factories called foundries. Over 70% of all metal castings are produced via a sand casting process; Sand casting is relatively cheap and sufficiently refractory even for steel foundry use. 2) Die casting: Die casting Die casting is a metal casting process that is characterized by forcing molten metal under high pressure into a mold cavity. The mold cavity is created using two hardened tool steel dies which have been machined into shape and work similarly to an injection mold during the process. 3) Permanent mold casting: is metal casting process that employs reusable molds ("permanent molds"), usually made from metal. The most common process uses gravity to fill the mold, however gas pressure or a vacuum are also used. A variation on the typical gravity casting process, called slush casting, produces hollow castings Dept of Mechanical Engineering 3 Manufacturing Process 4) Investment casting: is an industrial process based on and also called lost-wax casting, one of the oldest known metal-forming techniques .From 5,000 years ago, when bees wax formed the pattern, to today’s high-technology waxes, refractory materials and specialist alloys, the castings allow the production of components with accuracy, repeatability, versatility and integrity in a variety of metals and high-performance alloys. 5) Centrifugal casting: Centrifugal casting or roto-casting is a casting technique that is typically used to cast thinwalled cylinders. It is noted for the high quality of the results attainable, particularly for precise control of their metallurgy and crystal structure. TERMS INVOLVED IN CASTING 1. Flask: A metal or wood frame, without fixed top or bottom, in which the mold is formed. Depending upon the position of the flask in the molding structure, it is referred to by various names such as drag- lower molding flask, cope- upper molding flask, cheek - intermediate molding flask used in three piece molding. 2. Pattern: It is the replica of the final object to be made. The mold cavity is made with the help of pattern. 3. Parting line: This is the dividing line between the two molding flasks that makes up the mold. 4. Molding sand: Sand, which binds strongly without losing its permeability to air or gases. It is a mixture of silica sand, clay, and moisture in appropriate proportions. 5. Facing sand: The small amount of carbonaceous material sprinkled on the inner surface of the mold cavity to give a better surface finish to the castings. Dept of Mechanical Engineering 4 Manufacturing Process 6. Core: A separate part of the mold, made of sand and generally baked, which is used to create openings and various shaped cavities in the castings. 7. Pouring basin: A small funnel shaped cavity at the top of the mold into which the molten metal is poured. 8. Sprue: The passage through which the molten metal, from the pouring basin, reaches the mold cavity. In many cases it controls the flow of metal into the mold. 9. Runner: The channel through which the molten metal is carried from the sprue to the gate. 10. Gate: A channel through which the molten metal enters the mold cavity. 11. Chaplets: Chaplets are used to support the cores inside the mold cavity to take care of its own weight and overcome the metallo static force. 12. Riser: A column of molten metal placed in the mold to feed the castings as it shrinks and solidifies. Also known as "feed head". 13. Vent: Small opening in the mold to facilitate escape of air and gases. STEPS IN MAKING SAND CASTINGS There are six basic steps in making sand castings: 1. Patternmaking 2. Core making 3. Molding 4. Melting and pouring 5. Cleaning 1. Pattern making: a pattern is a replica of an object to be cast. It is used to prepare a cavity into which the molten metal is poured. A skilled pattern maker prepares the pattern using wood, metal, plastic or other materials with the help of machines and special tools. Many factors like durability, allowance for shrinkage and machining etc are considered while making a pattern. 2. Molding: mould preparation involves forming a cavity by packing sand around a pattern enclosed in a supporting metallic frame called flask (mould box). When the pattern is removed from the mould, an exact shaped cavity remains into which the molten metal is poured. Gating and risering are provided at suitable locations in the mould. Dept of Mechanical Engineering 5 Manufacturing Process 3. Core making: Cores are forms, usually made of sand, which are placed into a mold cavity to form the interior surfaces of castings. Thus the void space between the core and mold-cavity surface is what eventually the casting becomes. 3. 4. Melting and Pouring: metals or alloys of the required composition are melted in a furnace and then transferred (poured) into the mould cavity. Many factors like temperature of molten metal, pouring time, turbulence etc, should be considered while melting and pouring. 5. Cleaning and Inspection: after the molten metal has solidified and cooled, the rough casting is removed from the mould, cleaned and dressed (removing cores, adhered sand particles, gating and risering systems, fins, blisters etc, from the casting surface) and then sent for inspection to check for dimensions or any defects like blow holes, cracks, etc. PROCEDURE FOR MAKING A CASTING: a. Place the pattern in the drag box b. Ram moulding sand around the pattern and till the top surface of the drag box c. Level the sand in the drag box d. Drag box is inverted, so that pattern is visible at the top surface. e. Place the cope on top of the drag box. Place riser and sprue at proper location and ram sand into the cope box. Dept of Mechanical Engineering 6 Manufacturing Process f. Cope box is rammed till its top surface. Riser & sprue are removed. g. Cope box is lifted and placed aside h. Pattern is removed from the drag box. Gates are cut. Dept of Mechanical Engineering 7 Manufacturing Process i. Sand core prepared in core box. j. Core is placed in drag box. k. Cope is placed on drag & mould made ready for pouring. ADVANTAGES OF CASTING PROCESS: 1. Molten metal flows into small ant section in the molten cavity. Hence any complex shape can be easily produced. 2. Practically any material can be casted.
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